Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

PANEL REPAIRS
-14 PROCEDURES
5.Separate spot welded joints and remove panel 
remnants using hammer, bolster, chisel and 
pincers.
Prepare old surfaces
1.Clean all panel joint edges to a bright smooth 
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining 
sealant using a hot air gun to minimise the risk 
of toxic fumes caused by generated heat.
Caution: Care must be taken to avoid 
excessive heat build up when using this 
equipment.2.Straighten existing panel joint edges using a...

PANEL REPAIRS
PROCEDURES -15
2.Cut new and existing panels as necessary to 
form butt, joggle or brace joint as required. 
Remove all clamps and metal remnants.
3.Prepare new panel joint edges for welding by 
sanding to a bright finish. This must include 
inner as well as outer faces.
4.Apply suitable weld-through primer, to panel 
joint surfaces to be welded, using brush or 
aerosol can.5.Apply adhesive sealant to panel joint surfaces.
Offer up and align
1.Offer up new panel and align with associated...

PANEL REPAIRS
-16 PROCEDURES
2.Fit resistance spot welding arms and test 
equipment for satisfactory operation, using test 
coupons. Where monitoring equipment is not 
available, verify weld strength by checking that  
metal around the weld puddle pulls apart under 
tension during pulling.
3.Use a resistance spot welder where access 
permits. Try to  ensure weld quality by using a 
welding monitor where possible. 4.MIG tack weld butt joints and re-check 
alignment and panel  contours where 
n e c e s s a...

PANEL REPAIRS
PROCEDURES -17
6.MIG seam weld butt joints. When MIG welding 
long joints, a large amount of heat is generated 
which can cause the panels to distort. To avoid 
heat distortion, divide the welds into small 
sections as shown on the illustration. The large 
arrows signifies the direction of welding.
7.Always use MIG plug welds where excessive 
metal thickness or limited access make 
resistance spot welding impractical. Make plug 
welds either by using holes left by the spot weld 
cutter, or...

PANEL REPAIRS
-18 PROCEDURES 

PANEL REPAIRS
REPAIRS -19
REPAIRS
Front bulkhead assembly 
In this procedure, the headlamp mounting panels 
and the bonnet locking platform are removed. 
Remove
1.Disconnect battery earth lead.
CAUTION: After switching off the ignition, 
wait 2 minutes before disconnecting the 
battery. Failure to wait two minutes will 
damage the navigation computer.
2.Remove both headlamp assemblies.
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
3.Remove front bumper.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly...

PANEL REPAIRS
-20 REPAIRS
Bonnet locking platform
The bonnet locking platform is bolted in position, 
there are no welds to hold it in place.
Remove
1.Remove both headlamp assemblies. 
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
2.Remove LH and RH bonnet locks.
3. Diesel models: Remove fuel cooler air duct.
4.Remove 3 screws securing grille to bonnet 
locking platform.
5.Remove bolts securing bonnet locking platform 
and remove platform.
Refit
1.Position bonnet locking platform, align to 
correct...

PANEL REPAIRS
REPAIRS -21
Radiator protection bar
Remove
1.Disconnect battery earth lead.
2.Remove headlamp mounting panel.
 
 +  , , Headlamp mounting panel.
3.Remove RH headlamp mounting panel.
4.Remove nut securing PAS hose mounting to 
radiator protection bar and move hose aside.
5.Remove 2 bolts securing radiator protection bar 
to front sub-frame and with assistance remove 
from vehicle.
NOTE: Do not carry out further dismantling if 
component is removed for access only.
6. V8 models only: Remove...

PANEL REPAIRS
-22 REPAIRS
Refit
1. LH side: Fit windscreen washer reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
2. Diesel models: Fit and connect intercooler 
pipes.
3. RH side: Fit gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
4. LH side: Fit radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
5.Fit radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
6.Fit front armature....

PANEL REPAIRS
REPAIRS -23
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit PAS pipes.
2.Fit front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
3. LH side: Fit alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
4. LH side: Fit windscreen washer reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS,...